Curved Foldable Tailored Fiber Reinforcements for Moldless Customized Bio-Composite Structures. Proof of Concept: Biomimetic NFRP Stools

Fiber Reinforced Polymers (FRPs) are increasingly popular building materials, mainly because of their high strength to weight ratio. Despite these beneficial properties, these composites are often fabricated in standardized mass production. This research aims to eliminate costly molds in order to simplify the fabrication and allow for a higher degree of customization. Complex three-dimensional shapes were instead achieved by a flat reinforcement, which was resin infused and curved folded into a spatial object before hardening. Structural stability was gained through geometries with closed cross-sections. To enable this, the resource-saving additive fabrication technique of tailored fiber placement (TFP) was chosen. This method allowed for precise fibers' deposition, making a programmed anisotropic behavior of the material possible. Principles regarding the fiber placement were transferred from a biological role-model. Five functional stools were produced as demonstrators to prove the functionality and advantages of the explained system. Partially bio-based materials were applied to fabricate the stool models of natural fiber-reinforced polymer composites (NFRP). A parametric design tool for the global design and fiber layout generation was developed. As a result, varieties of customized components can be produced without increasing the design and manufacturing effort.